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Design and Modal Analysis of Composite Drive Shaft For Automotive Application
Design and Modal Analysis of Composite Drive Shaft For Automotive Application
t
=
=
2 2 2
2
2
l t t l lt
lr tr lr ltr
o o o o t
o
o o o t
( ( (
+ + =
( ( (
Mohammad Reza Khoshravan et al. / International Journal of Engineering Science and Technology (IJEST)
ISSN : 0975-5462 Vol. 3 No. 4 April 2011 2545
Where N
cr
is the critical speed and f is the bending frequency. Considering that the natural frequency of a shaft
according to the above equation is inversely proportional to the square of shaft's length and is proportional to the
square root of Young's module, conventional steel drive shafts are made of two pieces to increase the natural
frequency of the shaft, which results in overall increase in weight of shaft. So, in order to increase the natural
frequency, the length of shaft should be reduced or
/ E
ratio should be increased. Despite the space limitations
that confines outer diameter of the shaft, the only way to increase the critical speed is to increase / E ratio
(Specific module) [3].
One of the interesting properties of metals is that although there is a clear difference in their density, their
specific modulus is almost constant. With applying fiber-reinforced composites, fiber orientation arrangement
becomes possible in the shaft; therefore, bending modulus will be high. Also their relative density is low leading
to the desirable specific modulus and increases the critical speed [5].
The natural frequency of the shaft was obtained through Timoshenko theory as following equation:
2 2
2
30
2
nt s
p Er
f K
L
t
=
(3)
Where
nt
f is the natural frequency, p is the first natural frequency and ,E are properties of the steel shaft.
s
K
is
given by following equation:
2 2 2
2 2
1
1 1
2
s
s
f E p r
K L G
t (
= + +
(
(4)
Where the G is modulus of rigidity of steel shaft and
s
f is equal to 2 for hollow cross sections. Then critical
speed is obtained in following way [3]:
60
cr nt
N f = (5)
3.2. Modal analysis of composite drive shaft using ANSYS
In this study, finite element analysis is conducted using ANSYS software. To model the composite drive shaft
Shell 99 element is used and it is subjected to torque. The shaft is fixed at both ends and is subjected to torque at
the middle. Figure 3 shows the domain of finite element mesh. Once the finite element mesh and the layers are
created, orientation of materials is defined for the shell element and layer materials for each of these elements
are being allocated. The other steps include placing the boundary conditions and selecting appropriate solvers.
The shaft rotates with maximum speed so the design should include a critical frequency. If the shaft rotates at its
natural frequency, it can be severely vibrated or even collapsed. The modal analysis is performed to find the
natural frequencies in lateral directions. The mode shapes for all material combinations are obtained to their
corresponding critical speeds. A number of fundamental modes, which all are critical frequencies, are obtained.
If the shaft's frequencies correspond to these ones, it may be collapsed.
The dynamic analysis shows that the first natural frequency is 169.64 Hz, and according to it the critical speed is
equal to 10178 rpm, which is much more than the critical rotational speed of 4000 rpm. According to the
equations obtained in previous section, natural frequency of a specific composite drive shaft is 4570.2 rpm. This
value is very different from the initial value because the correlations used to obtain the values associated with
the shaft, were in case of considering some assumptions.
Figure 4 depicts the deformation rate change for composite drive shaft at the first natural frequency. Figures 5 to
8 show the displacement rate of composite drive shaft in different directions at first mode. The natural
frequencies of composite drive shaft are given in Table 2.
Mohammad Reza Khoshravan et al. / International Journal of Engineering Science and Technology (IJEST)
ISSN : 0975-5462 Vol. 3 No. 4 April 2011 2546
Figure 3. The mesh configuration of composite shaft Figure 4. The deformation formof composite shaft at first mode
Figure 5. The displacement rate of composite shaft Figure 6. The displacement rate of composite shaft
in x-direction at first mode in y-direction at first mode
Figure 7. The displacement rate of composite shaft Figure 8. The total displacement contour of composite shaft at
in z-direction at first mode first mode
Table 2. Natural frequencies of composite drive shaft
Frequency
Number
Frequency
(Hz)
1 169.64
2 182.67
3 226.73
4 255.98
5 278.44
Mohammad Reza Khoshravan et al. / International Journal of Engineering Science and Technology (IJEST)
ISSN : 0975-5462 Vol. 3 No. 4 April 2011 2547
4. Design of adhesive joints in composite drive shafts
The joints used for connecting composite materials can be metallic or non-metallic. Steel fasteners due to the
possibility of galvanic corrosion with carbon-epoxy materials, are mainly made of titanium or stainless steel.
Other alloys such as aluminum or steel can be used provided that no contact with the surface is occurred. J oints
are divided to metal screws and rivets. Non-metallic connectors are created from reinforced thermo set or
thermoplastic resins. By using this connection, structural weight reduces and corrosion problems disappear [6].
In this part, firstly the thickness of the adhesive and length of adhesive bond are computed. Then, a finite
element analysis of this type of bond is performed using ANSYS software.
The "Araldite" adhesive was used in this study. The following correlations were used to calculate the required
parameters:
max
2
tanh
2
m
c
c
a
a
G l
a
Gee
t t =
=
(6)
Where l is the length of adhesive bond. For obtaining reasonable results the only possible way is to increase the
value of e. so, the thickness of the adhesive and the length of the adhesive bond are obtained 12 millimeters and
4.5 centimeters, respectively. The details of the bond are given in Table 3.
Table 3. Mechanical properties of the adhesive
Property Value
E
2.5 Gpa
G 1 Gpa
c
e 0.25
l 45 mm
Layers orientation
For analysis, a FE model was applied using the 3 - D linear solid elements. A suitable mesh for finite
element modeling of adhesive layer is needed. The shear distribution stress of the adhesive is shown in
Figure 9. Application of appropriate adhesive, results in decreased maximum shear stresse in adhesive at the
edges of the connection; however, if the stresses remain same in the middle connection, start of failure will
depend on the relative shear strength values in the adhesive.
Figure 9. Shear stress distribution in the adhesive bond connection
6
[ 45/ 0 / 45]
T
Mohammad Reza Khoshravan et al. / International Journal of Engineering Science and Technology (IJEST)
ISSN : 0975-5462 Vol. 3 No. 4 April 2011 2548
5. The weight comparison between composite and steel drive shafts
The entire of vehicle drive shaft is consisted of several rotating masses. About 17-22% of the power
generated by the engine is wasted due to rotating mass of power train system. Power is lost because a lot of
energy is needed to rotate heavy parts. This energy loss can be reduced by decreasing the amount of rotating
mass. Table 4 represents the comparison of inertia moment between composite and steel drive shafts.
Table 4. Comparison of inertia moment between composite and steel drive shafts
2
( . )
m
I Kg mm
4
( ) I mm
18370.9
6
0.57 10
Steel
9945
6
1.59 10
Composite
45.8% 64.1% % Diffrence
In Figures 10, a mass comparison between steel and composite drive shafts has been done.
Figure 10. Mass comparison between steel and composite shaft
6. Conclusion
In this paper a one-piece composite drive shaft is considered to be replaced a two-piece steel drive shaft. Its
design procedure is studied and along with finite element analysis some important parameter are obtained.
The composite drive shaft made up of high modulus carbon / epoxy multilayered composites has been designed.
The replacement of composite materials has resulted in considerable amount of weight reduction about 72%
when compared to conventional steel shaft. Also, the results reveal that the orientation of fibers has great
influence on the dynamic characteristics of the composite shafts.
References
[1] Gay, D.; V. Hoa, S.; W. Tsai, S. (2004). Composite materials: design and application, CRC press.
[2] Pollard, A.; (1999): Polymer matrix composite in drive line applications. GKN technology, Wolverhampton.
[3] Rangaswamy, T.; Vijayrangan, S. (2005). Optimal sizing and stacking sequence of composite drive shafts. Materials science, Vol. 11
No 2., India.
[4] Rastogi, N. (2004). Design of composite drive shafts for automotive applications. Visteon Corporation, SAE technical paper series.
[5] Lee, D. G.; Kim, H. S.; Kim, J . W.; Kim, J . K. (2004). Design and manufacture of an automotive hybrid aluminum/composite
driveshaft, composite structures, (63): 87-99.
[6] Pappada, S.; Rametto R. (2002). Study of a composite to metal tubular joint. Department of Materials and Structures Engineering ,
Technologies and Process, CETMA , Italy
0
2
4
6
8
10
12
Weight
Composite
Steel
Mohammad Reza Khoshravan et al. / International Journal of Engineering Science and Technology (IJEST)
ISSN : 0975-5462 Vol. 3 No. 4 April 2011 2549